REQUEST FOR PROPOSALS FOR SLUDGE DEWATERING EQUIPMENT HORTONVILLE WASTEWATER TREATMENT FACILITY VILLAGE OF HORTONVILLE.

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1 REQUEST FOR PROPOSALS FOR SLUDGE DEWATERING EQUIPMENT HORTONVILLE WASTEWATER TREATMENT FACILITY VILLAGE OF HORTONVILLE August 4, 2016 The Village of Hortonville, Wisconsin is requesting proposals for sludge dewatering equipment. Bids will be received by the Village of Hortonville, 531 N. Nash St., Hortonville, WI until 2:00 p.m. CDT, Wednesday August 31, Firms responding to this Request for Proposal (RFP) need only submit Two (2) hard copies to: Village of Hortonville Attn: DPW RE: RFP Screw Press 531 N. Nash St. P.O. Box 99 Hortonville, WI The Village of Hortonville is located in western Outagamie County, Wisconsin and maintains miles of streets, 16.5 miles of sanitary sewers, 3 lift stations, and 16.9 miles of water mains, 173 hydrants, 1,278 meters, a WPDES licensed 0.8 mgd WWTF, an elevated water storage tank, two municipal wells, and seven park-related facilities. The Village has an estimated population of 2711 residing in a 3.3 square mile area. The Village intends to continue providing a high level of commitment to quality customer service. In procuring the services described in this Request for Proposal (RFP), the Village is seeking a professional vendor committed to high quality public service.

2 Contents Design Parameters... 3 Pre-Bid Conference... 3 Submittals... 4 Quality Assurance... 4 Delivery, Storage, and Handling of Equipment... 5 Acceptable Manufacturers... 6 Sludge Characteristics Hortonville WWTP... 7 Sludge Dewatering Press Design Specifications... 8 Execution Warranty Bid Security Payment and Performance Bond Certificate of Insurance Indemnity Liability Withdraw of Bids Miscellaneous... 13

3 Design Parameters General Scope A. Contractor shall furnish and install on (1) sludge dewatering screw press. The screw press shall be manufactured from AISI 304 stainless steel shapes. Fabrication and assembly shall be in conformance with these specifications. B. Contractor shall furnished a complete dewatering system including screw press, drive motors, gear reducers, support legs, anchor bolts, polymer station, feed pump, all piping and wiring controls, all electrical connections, and all accessories, miscellaneous equipment and appurtenances specified or otherwise required for a compete and properly operating installation. 1. Provide a general fault alarm to existing SCADA system. 2. Minimum discharge clearance of 30 inches above floor. C. Contractor shall coordinate all details of the installation and functionality of the new equipment with other related parts of the work and existing systems. Contractor shall verify that all structures, piping, wiring, and equipment are compatible with other related parts of the new and existing systems. Contractor shall be responsible for all structural and other alterations required to accommodate equipment. D. Contractor shall install the equipment according to instructions and recommendations of the equipment manufacturer. E. Available power supply is 460 Volts, 60 Hz, 3-phase. The polymer system should operate on a separate 120 VAC, 60 Hz, single-phase power supply. F. Bidder must call out any differences from specifications. G. Bidder must visit site to verify all project design and integration requirements prior to bidding. Pre-Bid Conference A pre-bid conference will be held at the Hortonville Waste Water Treatment Facility, 521 W. Cedar St. on August 11 th at 10:00 a.m.. Representatives of the Village will be present to discuss the Project. Bidders are encouraged to attend and participate in the conference. Reference A. American Society for Testing and Materials (ASTM) Publications: 1. Section A322: Carbon and Alloy Steel Bar Specifications. 2. Section A507-10: Standard Specification for Drawing Alloy Steel, Sheet and Strip, Hot- Rolled and Cold Rolled. B. Anti-Friction Bearing Manufactures Association(AFBMA) Publications: 1. Standard 9-90 Load Ratings and Fatigue Life for Ball Bearings. 2. Standard Load Ratings and Fatigue Life for Roller Bearings. C. American Institute of Steel Construction (AISC) Publications D. American Welding Society (AWS) Publications E. American Structures Painting Council (ASPC) Publications

4 Submittals The following information shall be submitted to the Village, including copies of all materials required to establish compliance with this Section. Submittals shall include the following: A. Product Data: Include the following: 1. Descriptive literature, brochures, catalogs, cut-sheets and other detailed descriptive material of the equipment. 2. Motor characteristics and performance information. 3. Gear reducer data including service factor, efficiency, torque rating, and materials. 4. Parts list including a list of recommended spare parts. A. Shop Drawings: Include the following: 1. Manufacturer s installation drawings. 2. Wiring and schematic diagrams. 3. Equipment weights and lifting points. B. Operations and maintenance manual. C. Detailed installation instructions, with clear step-by-step points on the correct mechanical and electrical installation procedures. D. Recommendations for short and long-term storage. E. The Contractor shall guarantee the work be free from defects in material and workmanship for a period of one year from the date of commencement of use. F. A copy of documents proving certification of the Manufacturer s Quality Management System according to ISO 9001 and Environmental Protection Management System according to ISO G. Failure to include all drawings applicable to the equipment specified in this section will result in rejection of the entire submittal with no further review. Quality Assurance A. To ensure quality, conformance, and reliability with regard to the manufacturing and production of the machinery described in this section, the equipment manufacturer shall meet the requirements listed in this section. B. Manufacturer shall have established an ISO 9001 certified quality management system. C. Manufacturer shall have established an ISO certified environmental protection management system. D. All stainless steel components and structures shall be submersed in a chemical bath of nitric acid and hydrofluoric acid (pickling bath) to remove any residues that may be present on the material as a result of forming, manufacture, or handling. After removal from the pickling bath, the equipment must be washed with a high-pressure wash of cold water to remove any remaining surface debris and promote the formation of an oxidized passive layer which is critical to the long life of the stainless steel. No stainless steel components may be fabricated or

5 assembled in a factory where carbon steel products are also fabricated, in order to prevent contamination by rust. E. Screw Press shall be manufacturer s standard product and only be modified as necessary to comply with the drawings, specifications and specified service conditions. F. All welding is performed in accordance with American Welding Society (AWS) D1.1 Structural Welding Code, or equivalent. G. Manufacturer shall provide screw press, polymer system, motors, gear reducers, controls, control panels, and lifting attachments as a complete integrated package to ensure proper coordination, compatibility, and operation of the system. H. Manufacturer shall provide services by a factory-trained service engineer, specifically trained on the type of equipment specified. Service engineer requirements include, but are not limited to the following: 1. Service engineer shall be present during initial energizing of equipment to determine directional testing. 2. Service engineer shall inspect and verify location of anchor bolts, placement, leveling, alignment and field erection of equipment, as well as control panel operation and electrical connections. 3. Service engineer shall provide field training on the operations and maintenance of the equipment to Village staff. 4. Manufacturer shall state field service rates for a service engineer to owner and contractor. In the event that the field service time required by this section should not be sufficient to properly place the equipment into operation, additional time shall be purchased by contractor to correct deficiencies in installation, equipment or material without additional cost to owner. I. Contractor shall guarantee all equipment against faulty or inadequate design, improper assembly or installation, defective workmanship or materials, and breakage or other failure. Materials shall be suitable for service conditions. J. All equipment shall be designed, fabricated, and assembled in accordance with recognized and acceptable engineering and shop practice. Individual parts shall be manufactured to standard sized and thickness so that repair parts can be installed in the field. Like parts of duplicate units shall be interchangeable. Equipment shall not have been in service prior to delivery, except as required by testing. K. Each major component of equipment shall have the manufacturer s name, address and product identification on a nameplate securely affixed to the equipment. Delivery, Storage, and Handling of Equipment A. Equipment shall be shipped and delivered fully assembled, except where partial disassembly is required in order to conform to transportation regulations or for the protection of components. B. Contractor shall be responsible for unloading and shall have equipment on-site at the time of delivery permitting proper hoisting of the equipment.

6 Acceptable Manufacturers A. ROTAMAT sludge Dewatering System Model RoS3 Q280 from Huber Technology, Inc. B. Kusters Water/ACAT Screw Press, Model AS450 C. Liquid polymer blending system: Veloblend VM-P from Velocity Dynamics, Inc. or equivalent Alternate Equipment Manufactures Alternatives should include the following information and supporting documentation. A. A complete set of drawings, specifications, catalog cut-sheets, and detailed descriptive material. Drawings shall show all relevant details of the unit. This information shall identify all technical and performance requirements stipulated on the drawings and in the specifications. If the proposed equipment does not meet these specifications, any deviation from the specification must be expressly notes. All deviations shall be listed on a single document. B. Detailed installation drawings illustrating how the proposed screw press will be installed. The drawings shall include plan, elevation, and sectional views of the installation. Drawings shall include details of the injections ring, mixing valve, flocculation reactor, and details of the anchor bolt locations. C. Motor characteristics and performance information. Vendor data shall be furnished to confirm the torque and thrust rating of the drive. D. Reference list of installations of same or similar equipment including contact names and phone numbers. E. Complete bill of materials for all equipment, showing dimensions and materials of construction of all components. F. Certification by the manufacture that all stainless steel equipment will be manufactures in a stainless steel only factory. G. Certification that the entire equipment will be passivated by submersion in an acid bath. H. A copy of documents proving certification of the Manufacturer s Quality Management System according to ISO 9001 and Environmental Protection Management System according to ISO I. Details of the control and instrumentation system including wiring diagrams. J. Details of the control and instrumentation system including total weight of assembled components and weight of each sub-assembly K. List of recommended spare parts. L. A maintenance schedule showing the required maintenance period, including all buy-out items.

7 Sludge Characteristics Hortonville WWTP Upstream Process: Digestion Process: Sludge Type: Sequencing Batch Reactor Aerobic Digester WAS Screw press feed source: WWTP sludge storage tank mix pump piping A. Sludge to be dewatered will be well-mixed and well blended having the following characteristic: 1. Sludge feed rate: 10,000 to 12,000 gal/wk 2. Operational schedule: 21 hr/wk 3. Solids concentration: 1.5% - 2% 4. Hydraulic loading rate: 10 gpm 5. Solids loading rate: 75 lb/hr B. Dewatering screw press shall be capable of dewatering 10 Gallons per Minute (GPM) of the specified municipal wastewater sludge to a final solids content of 18% to 20%. The solids capture rate shall be a minimum of 95%. The polymer consumption shall not exceed 40 lbs. of active polymer substance per ton of sludge solids fed. C. The sludge dewatering plant consists of the following major parts: 1. Screw Press incl. support legs 2. Polymer dosing system 3. Feed pump system, including all supply and waste piping components 4. Control panel D. All parts of the dewatering press shall be designed and appropriated for the service specified and indicated and for continuous operation. E. Sufficient room for inspection, maintenance, repair and adjustment shall be provided. Contractor shall provide hoisting equipment to facilitate installation and maintenance work. F. The physical layout should be verified by contractor. Contractor shall include in the bid all necessary modifications to the piping, electrical, structural, and mechanical layouts to accommodate the equipment proposed. Contractor shall supply modified drawings. G. All parts shall be designed and manufactured to handle the forces that may be exerted on the screw press during fabrication, shipping, erection, and proper operation according to the O&M manual. H. All components shall be so arranged that they can be serviced from the operating floor. I. All components shall be labeled so that jamming at any point will not result in structural failure, but will cause the drive motor to stall. All components, including the gear reducer, shall be designed to withstand, without damage or permanent distortion, the full stalling torque of the drive motor.

8 Sludge Dewatering Press Design Specifications Materials Design A. Sludge dewatering press shall be manufactured form AISI 304L stainless steel shapes (rod, angles, and channels), pipes and sheets. In particular, wedge wire basked, screw, shaft, covers, support legs, fasteners and anchors bolts shall be made of this material. B. Brushes for helical screw flights shall be of wear resistant plastic material. The brush (if used) is held in place by stainless steel clamps and bolts which can be easily removed. A. The screw press shall be installed at the optimum angle as specified by the manufacturer. Dewatering of the sludge takes place in a basket assembly through increased pressure zones. B. The screen press shall be completely enclosed to prevent odor emission. The whole dewatering section and basket area shall be easily accessible through an inspection lid or cover. C. A screw shall be installed inside of the screen basket, the screw transports the sludge from the inlet to the discharge area at the end of the pressure zone. Its shaft diameter shall be conical towards the discharge section of the machine. The flights of the helical screw shall be provided with brushes to clean the wedge wire screen from the inside. D. The screw shall be shafted and shall be made of stainless steel. A shaft-less screw is not acceptable. A bearing shall support the discharge end of the screw shaft. Wear strips are not acceptable. E. A screw drive shall be provided at the sludge feed side of the press. The nominal motor power shall be 0.5 HP. The motor speed shall be controlled with a VFD. The drive unit shall be directly coupled to the screw shaft through a gearbox. F. The cleaning of the wedge wire screen from the outside shall be performed with a stationary spray bar washing system made of stainless steel piping and spray nozzles, the spray area shall run the entire length of the screen. One solenoid valve shall control the flow to the spray bar washing system. If a cleaning cycle is initiated, the screw press motor reverses and rotates the basked, until has completed a 360-degree rotation ensuring the entire surface area of the screen is cleaned. Contractor shall provide for connection of the water supply piping to the manifold of the backwash spray system. G. Spray water supply shall be designed for a minimum low of 18 GPM (filtered non-potable water re-use water is available at a maximum pressure of 50 PSI). Water pressure at each nozzle of the spray bar shall be a minimum of 50 PSIG. Average spray water consumption shall not exceed 14 to 20 Gallons at 50-PSI minimum per wash cycle. The use of re-use water is not mandatory, non-potable water is available at higher psi. H. A pneumatically actuated cone (or similar) that serves for adjusting the pressure in the pressure zone shall be provided at the discharge end of the screening basket, any pressurized air supply needed for operation shall be provide by the contractor. I. Sludge cake shall be automatically discharged through a rectangular sludge discharge opening. The discharge height shall be minimum 30 in above floor level.

9 J. Contractor shall provide a drain line for the filtrate and connect to the bottom drain connections of the screw press. The drain line shall also be provided with a flush connection with manual ball valve. Internal Piping A. Contractor shall provide and install a sludge feed pump. The sludge feed pump shall be of the progressive cavity type. The pump shall be controlled through a variable frequency controller (VFD) which is accepting a pacing signal from the screw press control panel, supplied by the manufacturer of the screw press. B. Contractor shall provide sludge feed pipe from the sludge feed pump (with VFD) through a magnetic-inductive flow meter through a polymer-dosing ring, polymer mixing valve. C. Polymer dosing ring and polymer mixing valve shall be supplied by the screw press manufacturer. D. Pipe flocculator to be supplied by the contractor and shall provide a minimum retention time of 45 seconds at design flow for the polymer and sludge mixture. E. The design of the flocculation pipe reactor shall be approved by the screw press manufacturer. F. The size of the piping needs to take into account: maximum capacity, loading rate, minimum velocity in piping to avoid sedimentation and conditions which do not negatively impact the flocculation process. Drive A. The press screw shall be driven by a shaft mounted gearbox and motor assembly. The gear reducer shall be bolted to a machined flange welded to the end of the press. B. The gear reducer shall be driven by a 1,680 rpm, 3-phase, 60 Hertz, 230/460 volt, Class 1, Division 2 continuous-duty motor with a conduit box suitable for outdoor operation. The motor power shall be 0.5hp. C. The output speed of the gear reducer shall be approximately 1.5 rpm at frequency of 60 Hz. D. Chain-drives, belt drives, hydraulic drives or a separate upper bearing for the transport screw will not be acceptable for this project. Polymer Dosing System for Liquid Polymer A. System shall be designed for the preparation, aging and dosing of up to 40 GPM of polymer solution having an active polymer concentration between 0.05 and 0.25%. The actual size of the polymer system depends on the specified type of sludge, maximum capacity and polymer consumption. B. The polymer station shall be self-contained with pumps, piping, fittings and accessories, and shall be factory assembled and tested to eliminate field assembly work and therefore to minimize installation and start up time.

10 C. A polymer mixing chamber shall be provided. A high energy, multi zoned, hydro-mechanical mixing device shall be provided. The mixing chamber shall have a translucent front cover. D. The mechanical impeller shall be designed to produce variable intensity, backflow mixing action to optimize polymer performance without damaging the polymer s molecular structure. E. Motors shall be 0.5hp, 1750rpm, 90 V, 60Hz, wash down duty with keyless shaft and left hand impeller mounting screw. F. Materials: Impeller PVC; body of mixing devise PVC; cover clear lexan; fastener 316 SS; seals viton; pressure rating maximum 150 PSI. G. Contractor shall provide a potable water connection for the dilution of the polymer in the polymer tank. The water piping to the polymer blend system shall include a minimum one (1) inch inlet (NPT female), an UL listed solenoid valve (rated IP65), and a flow meter with a rate adjusting valve and low pressure alarm switch. H. A polymer metering pump with hose connector shall be provided and connected through a ½ inch barbed hose to the polymer mixing device. The neat polymer pump shall be a progressive cavity type pump. I. Polymer Control Panel: NEMA 4X FRP enclosure, 120 VAC, 60 Hz, 1 PH service. 1. Operator interface selector switch (system ON/OFF/REMOTE); mechanical mixer speed adjust potentiometer; stroke length/stroke speed adjustment at metering pump. 2. Status/Alarm indicators: system running indication; LCD display of metering pump rate (on metering pump); low-pressure switch alarm. 3. Inputs: remote start/stop (discrete dry contact); pacing signal from main control panel (4-20Ma). 4. Outputs: system running (discrete dry contract); remote mode (discrete dry contact); low-pressure alarm (discrete dry contact). J. The pressure side of the polymer system shall be connected through a minimum 1 inch diameter PVC pipeline and a magnetic inductive flow meter to the polymer injection ring describe above. K. The injection ring is the place where the polymer is added to the sludge. A mixing valve with adjustable weight follows to ensure optimum mixing conditions and creating the right size and strength of flocks. The retention time between the mixing valve and the dewatering machine shall be a minimum of 45 seconds at maximum flow. Controls and Instrumentation A. The entire control system shall be provided by the Manufacturer of the Screw Press. B. The contractor shall provide wiring between all system components as required. C. The contractor shall provide 460 V 60 Hz, 3 phase power supply to the main control panel and also a 120 V, 60Hz, single phase power supply to the control panel for the polymer system, D. The dewatering system shall be fully-automatic and shall include the following: 1. Main control panel for screw press 2. Polymer system control panel 3. Magnetic-inductive flow meter for thin sludge feed and polymer 4. Automatic control for the pneumatic pressure cone E. A 460-volt main control panel shall be provided in a NEM 4X related stainless steel enclosure. The enclosure shall be suitable for wall mounting, shall have hinged covers which swing

11 horizontally and shall be held closed with mechanical spring loaded fasteners, and shall include the following: 1. Main power disconnect switch (pad-lockable) 2. Control power transformer 3. Surge arrester 4. H-O-A control switches (screw drive including F/R selector switch, sludge pump, wash water solenoid valve) hp Variable Frequency Controller (VFD) including over-current and over-heat protection for screen press main drive 6. Variable Frequency Controller (VFD) including over-current and over-heat protection for thin sludge pump (positive displacement type). The size of the VFD is set a maximum 5.0hp. It is the engineer s responsibility to verify the exact motor size based on hydraulic conditions of the installation. 7. Programmable logic controller (PLC) Allen Bradley Compactlogic (or comparable) with on-board Ethernet. 8. Operator Interface (OIU), Allen Bradley Panelview 600 (or comparable) with color touch screen and Ethernet communication. 9. Running time meter for screen press, and feed pump. 10. Text messages displayed on touch screen: a. Over-current indications b. Spray bar washing system on c. Polymer dosing station status 11. Operating and warning lights for the following: a. Power on b. Dewatering system in operation c. Malfunction indication d. Reset button 12. Laminated plastic nametags shall be provided for the name of the control panel and all disconnects, switches, lights, and meters. 13. Spare terminals (control and power voltage) shall be provided to accommodate for remote control operations and to interface with other equipment components such as the polymer dosing system, thin sludge pumps etc. 14. Control panel (120VAC, single phase) for polymer dosing system shall be furnished by polymer dosing station supplier, to guarantee always a constant concentration in the dosing chamber, with the following features: a. Connection terminals and control and safety devices i. polymer make down system run signal ii. flow control neat polymer pump (accepting 4-20 ma signal) b. signals to main control panel: i. system run signal ii. malfunction polymer station c. Control panels shall be factory wired and pre-tested

12 Execution Installation, Start-up and Operator Training A. Contractor shall verify all dimensions in the field to ensure compliance of equipment dimensions with the drawings. Contractor shall notify Village of any deviations. B. Installation of the equipment shall be in strict accordance with the contract documents and the manufacturer s instructions and shop drawings. Manufacturer shall supply anchor bolts for the equipment. Contractors shall install the anchor bolts in accordance with the manufacturer s recommendations. C. After installation, touch-up paint shall be applied to all scratched, abraded and damaged shop painted surfaces. Coating type and color shall match shop painting. Contractor shall passivate all field welds. D. Supplier should furnish the services of a factory-trained service engineer for two (2) service days to inspect the installation and observe start up, and two (2) service days for operator training. 1. Equipment shall not be energized, or bumped to check the electrical connection for motor rotation without the service engineer present. 2. The service engineer shall make all necessary adjustments and settings to the controls. 3. The service engineer shall demonstrate proper and sequential operation of the dewatering system. The dewatering system shall be able to operate fully automatically. Warranty The manufacture will warrant against any defects in material or workmanship to the screw press, framework, and all appurtenances. This warranty will begin upon the date of commence of use and will expire twelve (12) months from that date (the Warranty Period ). Bid Security No bid shall be received unless accompanied by a Certified Check or satisfactory bid bond payable to the Village of Hortonville in an amount not less than 5% of the bid. Bid securities will be returned to all unsuccessful bidders. Payment and Performance Bond The Owner will require the awarded Contractor to provide a Performance/Payment Bond for the amount of the work. The cost of the bond shall be included in the base cost of the work. The surety providing the bond shall have rating of A+ or better as rated by A.M Best bond company ratings. Certificate of Insurance Contractor shall provide an Insurance Certification, as required by the Contract Documents, within ten (10) days after the Notice of Award.

13 Indemnity Contractor shall indemnify and hold harmless the Village for any claims whatsoever, not differentiated by kind or nature, made against the Village resulting from any actions or omissions on the part of the Contractor. Contractor shall indemnify and hold the Village of Hortonville, its officers, and its employees harmless from any and all suits, demands, costs, damages, claims, legal fees, or expenses including but not limited to reasonable attorney fees and court costs incurred by the Village in defending against any claims or in enforcing this provision against the Contractor, which may be incurred on account of damages, deaths, or injuries arising out of or related to the work being performed by the Contractor under the terms of the proposal. Liability Contractor shall provide proof of insurance with policies as follows: General Liability in an amount not less than $1,000,000, Property Damage in an amount not less than $1,000,000, Vehicle Liability not less than $500,000 per person and $1,000,000 per accident with a minimum liability umbrella of $1,000,000. Withdraw of Bids No Bid shall be withdrawn for a period of ninety (90) days after the scheduled opening without the consent of the Village. Miscellaneous A. The Village will source a belt conveyor/auger separately from this proposal. Contractor is welcome to bid a conveyance unit separately from this RFP. B. The Village will supply, install, and certify a backflow prevention device for the equipment. C. The Village will be modifying/constructing an addition onto the solids processing building, for the housing of the cake disposal dumpster. D. The Village has the right to accept the proposal deemed most advantageous, offers the best overall value, and is in the best interest of the Village. Deadline for Submission of Proposals. Two (2) copies of the proposal shall be marked RFP: Screw Press and submitted to the Village of Hortonville, at 531 N. Nash Street, Po Box 99, Hortonville, WI by 2:00 p.m. CDT on Wednesday, August 31, Inquiries and Additional Information Additional information may be obtained by calling the Village of Hortonville Director of Public Works, Carl McCrary, at or dpw@vohortonville.com